Control system for compensating for dimensional errors due to cutting tool wear in an automatic machine tool

ABSTRACT

A control system including apparatus which compensates for wear of the cutting tool. In a contouring control wherein the programmed instantaneous velocity along the contour is represented by a vector V, first and second compensating arrangements measure the motion of the first and second axes drive motors and multiply output signals indicative thereof by a geometrical function of the angle between the programmed tangential path of the cutting tool and one of the axis and by a factor related to the magnitude of tool wear to produce compensation signals. The compensation signals are applied to motor control loops to cause the actual tangential path of the cutting tool to be offset by a distance vector C which is normal to the vector V and has a magnitude equal to that of cutting tool wear.

United States Patent Rhoades 14 1 July 25, 1972 54 CONTROL Y TEM F R 3,328,655 6/1967 Tripp 318/572 x 3.430.035 2/1969 ma... 3 1 8/572 x COMPENSATING FOR DIMENSIONAL 3500.150 3/1970 Foster ..3l8/572 ERRORS DUE TO CUTTING TOOL WEAR IN AN AUTOMATIC MACHINE TOOL Inventor: John M. Rhoades, Waynesboro, Va.

Primary ExuminerBenjamin Dobeck A!l0rne \-William S. Wolfe et al.

[57] ABSTRACT [73] Assignee: General Electric Company A control system including apparatus which compensates for wear of the cutting tool. In a contouring control wherein the [22] Filed June 1971 programmed instantaneous velocity along the contour is [21] A L M 150,775 represented by a vector V, first and second compensating arrangements measure the motion of the first and second axes Related US. Application Data drive motors and multiply output signals indicative thereof by a geometrical function of the angle between the programmed [63] commuanon'm'pan of tangential path of the cutting tool and one of the axis and by a 1969' factor related to the ma nitude of tool wear to reduce comg p pensation signals. The compensation signals are applied to UcSe Clo... motor control loops to cause the actual tangential path of the [5 l Int. Cll 4 cutting tool to be offset by a distance vector C which is normal [58] Field of Search ..3l8/57l, 572 to the vector V and has a magnitude equal to that of cutting tool wear. [56] References Cited UNITED STATES PATENTS 22 Claims, 7 Drawing Figures 3,073,998 l/l963 Bower 318/572 YQ CLOCK POSITION LOOP\ 24Y 26Y 43v l I COMMAND PHASE DISCRIMINATOR 1 COUNTER SPEED c. 20 CLOCK 2| 42Y E EQLQJOY 2Y 2 4lY DATA FUNCTION INPUT UNIT GENERATOR 22x 40v 4|X 40X l 42x Qaox 24X 26X 27x 2 28X 29X I3 COMMAND PHASE DISCRIMINATOR CLOCK COUNTER 43x l i' l PATENTEB 2 5 I972 SHEET 1 0f 5 lNW/VTORQ JOHN M. RHOADES W M i HIS ATTORNEY PZITENTEDJUL 25 1912 SHEET 3 OF 5 I 85Y 86Y 87Y 88Y 89Y 9OY 8OY I I I I IOOY HIS ATTORNEY PATENTEnJuLzslsm 3.679.955

' SHEEI 4 0F 5 M/VE/VTOR. JOHN M. RHOADES BY 91 M 7 HIS ATTORBEY CONTROL SYSTEM FOR COMPENSATING FOR DIMENSIONAL ERRORS DUE TO CUTTING TOOL WEAR IN AN AUTOMATIC MACHINE TOOL BACKGROUND OF THE INVENTION This application is a continuation-in-part application Ser. No. 876,692 filed Nov. 14, 1969.

This invention relates to control systems for automatic machine tools. More specifically, it relates to a system for modifying the programmed motion of a cutting tool in an automatic machine tool to compensate for cutting tool wear.

In an automatic machine tool. a desired form is cut in a workpiece by moving the workpiece relative to a cutting tool within desired degrees of freedom. The relative motion is determined by command signals produced in response to instructions supplied to a data input means. The command signals are coupled to closed position control loops. each of which determines the motion of a servomotor which produces relative motion in one degree of freedom. Means are provided in each closed position control loop for comparing the actual position of each motor to its commanded position so that error signals areproduced and utilized to drive each motor as each command signal calls for further motion.

The instructions to the data input means are most conveniently in the form of a part program which may be provided from a punched paper tape. by setting some thumbwhcel switches on a control console or directly from a computer. A part program does not control the movement of the cutting tool directly but instead controls it indirectly by controlling the movement of a spindle in which the cutting tool is mounted. Thus. the spindle must be directed along a contour which is offset from the desired workpiece contour by a distance equal to the assumed radius of the cutting tool. At the time the part program is written, it is assumed the radius of the cutting tool is a constant. However, as a cutting tool operates over a large workpiece or over a long run of work pieces. it may wear appreciably.

"To ensure that a workpiece machined with a worn cutting tool has the same configuration and dimensions as a workpiece machined with a new cutting tool. it is necessary to compensate for cutting tool wear. Although it would be possible simply to offset the spindleperpendicularly to the line of movement if the cutting tool were always moved in a straight line, such an adjustment is not useful where the programmed motion of the cutting tool changes in velocity and direction. One course of action would be the replacement of a worn cutting tool with a new cutting tool having dimensions within a desired tolerance. This. however. results in the expense of providing a new cutting tool and causes downtime in machine operation. A new part program. taking into account the new dimensions of the cutting tool. could be provided. This course of action would result in machine downtime and excessive programming costs.

SUMMARY OF THE INVENTION The present invention is a control system for commanding the motion of a cutting tool in an automatic machine tool wherein the motion of the cutting tool is modified to compensate for cutting tool wear. The instantaneous velocity along the contour or tangential velocity of the cutting tool is represented by a vector V. An output indicative ofa first axial component of the vector V is supplied to a multiplier circuit having a gain which varies with the magnitude of the vector V. The multiplier circuit output is applied to an offset circuit having an input related to the magnitude of tool wear. The output of the offset circuit modifies the programmed movement along the second axis. In a similar manner. the second axial component of the vector V is an input to a circuit which provides a signal for modifying programmed movement along the first axis. The resultant of the compensating signals is represented by a distance vector C which is always normal to the vector V and has a magnitude equal to that oftool wear.

DESCRIPTION OF THE DRAWINGS The specification concludes with claims particularly pointing out and distinctly claiming that which is regarded as the present invention. Details of preferred embodiments of the present invention may be more readily ascertained by reference to the following description taken in connection with the accompanying drawings wherein:

FIG. I is an illustration of an automatic machine tool and a control console comprising a system constructed in accordance with the present invention;

FIG. 2 is an enlarged partial view illustrating the engagement ofa cutting tool with a workpiece;

FIG. 3 is a vector diagram useful in understanding the results achieved through the use of the present control system;

FIG. 4 is an illustration in block diagrammatic form illustrating the connection of a compensation circuit constructed in accordance with the present invention in a numerical control system;

FIG. 5 is a partially schematic and partially block diagrammatic representation of one form of compensating arrangement constructed in accordance with the present invention;

FIG. 6 is a partially schematic and partially block diagrammatic representation of another form of compensating circuit including mechanical means for automatically varying the magnitude of the compensating signal; and

FIG. 7 is a block diagrammatic representation of another form of the present invention including electronic means for automatically varying the magnitude of the compensating signal.

DETAILED DESCRIPTION Mechanical Operation In FIG. I. a control console-l incorporating circuitry constructed in accordance with the present invention is connected to provide command signals to operate an automatic machine tool 2. The automatic machine tool 2 includes a cutting tool 3 which engages a workpiece 4. The command signals are produced in response to a part program which may be provided in a number of ways. A series of thumbwhcel switches 5 may be manually set to determine the desired motion ofthe workpiece 4 with respect to cutting tool 3. Program data may also be provided from a punched paper tape reader 6 or directly from a computer (not shown).

The present invention is applicable to various forms of machine tools in which relative motion between a workpiece 4 and a cutting tool 3 is obtained by operating servomotors in response to command signals. The present analysis is with respect to a system in which movement in two perpendicular degrees of freedom is programmed. Referring to FIGS. I and 2 together. the cutting tool 3, which has an outer edge 8. is mounted on a spindle l0 and is moved in the vertical, or Y, direction by a servomotor I I. The workpiece 4 is mounted on a bed I2 movable in the horizontal, or X direction by a servomotor I3. The servomotors II and I3 may be hydraulic, electric or of any other suitable known type. In other machine tools relative motion between the cutting tool 3 and the workpiece 4 may be achieved in a different manner. In a lathe. for example. the workpiece 4 might be rotated on a spindle and servomotors may be provided to move a cutting tool along its length. Any two axes of the X. Y. or Z axes may be controlled in other types of machine tools.

The invention may be best understood by an analysis of its mechanical operation with reference to FIGS. 2 and 3 prior to a discussion of the circuitry shown in FIGS. 4-7. Although both cutting tool 3 and workpiece 4 may be in motion simultaneously. the discussion is simplied by referring to the relative motion as motion of the cutting tool.

In FIG. 2. a cutting tool is shown in a worn condition and a new condition. A new cutting tool. shown as a dotted circle. has a cutting edge 8. A worn cutting tool, shown in regular lined form, has a cutting edge 8'. Clearly. to machine a work piece having a desired contour whether with a worn or a new cutting tool, a numerical control system must have the capability of moving the cutting tool spindle along a path spaced from the desired contour by the existing radius R of the cutting tool. For example, to machine the vertical surface A of workpiece 4 a new cutting tool would be driven along the Y axis on a path parallel to but spaced from the desired vertical surface by the new tool radius R To machine the same surface, a worn cutting tool would be driven along the Y axis with its centerline on the radius R The difference between the radii R,, and R is caused by cutting tool wear.

lf tool movements were limited to movement along a single axis at a time, such as along the Y axis during machining of surface A or along the X axis during machining of horizontal surface B, tool wear could be compensated for simply by offsetting the cutting tool along the opposite axis by an amount equal to the change in cutting tool radius. In practice, arcuate and parabolic surfaces must be machined, making it impossible to use constant X or Y axis offsets. For curved surfaces such as surface B, the wear-compensating offsets must be along both axes and must change continuously with changes in the direction of movement of the cutting tool.

The present invention makes use of the fact that, regardless of the configuration of the surface being machined, the instantaneous direction of movement of the cutting tool spindle is parallel to a tangent to desired surface at the point of cutter contact with that surface. The movement of the cutting tool spindle at a particular time during the machining of curved surface B is represented by a vector V'having a magnitude determined by the programmed velocity along the contour and a direction determined by the programmed start (X,, Y, and finish (X Y points and the type ofinterpolation (circular) required. The instantaneous direction of the vector V can be defined by the angle which it forms with the X axis.

HO. 3 is a diagram ofthe vectoral components which come into play to compensate for cutter tool wear. Let it be assumed that the cutting tool 3 has worn so that an outer edge 8' is exposed which is closer to the center of the cutting tool than the original outer edge 8 by an increment d. In this situation. the position of the cutting tool center must be offset a distance :1 from the programmed position. The direction ofthis offset must be normal to the vector V and toward the surface being machined. The required offset is represented by a vector C. The X and Y components of the vector C. C, and C are superimposed on motion commands applied to X and r servomotors 11 and 13. Mathematieally, the axial components of C may be expressed. as:"

C u d Cos 0 (2) The direction or of vectors C, and C], depends on whether the cutting tool trajectory is to the right or the left of the workpiece surface.

Control Circuitry While the compensating circuit constructed in the present invention is suitable for use with many forms of control circuits, it is illustrated here in conjunction with a numerical control circuit. A means for commanding the uncompensated motion of the X and Y servomotors H and 13 is fully described in US. Pat. No. 3,173,001 to John T. Evans, assigned to the General Electric Company, which is also assignee hereof, and therefore is only briefly described here. A data input unit 20 produces signals for each machining step, including initial and final coordinates, interpolative functions which are required and the feedrate or velocity along the contour. By prior definition, the instantaneous movement of the cutting tool is represented by the vector V. The data input 20 may include the thumbwheel switches or punched paper tape 6 (FIG. I) and appropriate clock inputs and reference counters to produce output pulses indicative of the vector V or may itself be a computer output. The output pulses of the data input unit are coupled to a function generator 21. The function generator 21 resolves the output of the data input unit 20 into signals indicative of the desired Y and X components of motion needed to satisfy coordinate, interpolation and feedrate requirements contained in the input data. The output signal appearing at the terminal 22Y of the function generator 2] is coupled to one input ofa command phase counter 24Y. This input signal modulates a clock input signal fed to the command phase counter 24Y from a clock source to produce a phase-shifted square wave output from phase command counter 24Y which is indicative of the desired Y motion. A position transducer 25Y is mechanically coupled to the servomotor ll and also has an input from the clock source. The rotation of the position transducer 25Y modulates the clock input thereto to generate a phase-shifted output indicative of the actual position of the servomotor ll. The phase-shifted outputs of the command phase counter 24Y and position transducer 25Y are compared by a discriminator 26Y which produces an analog output related to the phase error therebetween. This analog output is the position command signal for the Y servomotor 11. The closed position loop comprises the Y servomotor II, the position resolver 25\' and discriminator 26Y. The Y position command signal is applied to an operational amplifier 27Y, the output of which is connected to a velocity loop operational amplifier 28Y. The output of the operational amplifier 28Y determines the degree of opening of a servo valve 29Y and hence the velocity of the hydraulic Y servomotor ll. A velocity transducer in the form of a tachometer generator 30Y is mechanically coupled to the Y servomotor 11 and its output is coupled to the input of the operational amplifier 28Y to close the velocity feedback loop.

The components denoted by corresponding reference numerals followed by the letter X perform similar functions to command the motion of the servomotor 13.

Compensation Circuitry First and second compensation circuits 40Y and 40X are capable of generating outputs which modify the analog signals commanding the motion of the servomotors II and 13 respectively to compensate for tool wear. The compensation circuit 40X has a first input terminal 41X connected to the output of the data input unit 20 and a second input terminal 42X connected to the output of the tachometer generator SOY. Similarly, the compensation circuit 40Y has one input terminal 4lY connected to the output of the data input unit 20 and another input terminal'42Y connected to the tachometer generator 30X. Stated generally, each compensation circuit in this embodiment of the invention receives one input indicative of the programmed tool velocity along the contour and another input indicative of the actual tool velocity along one ofthe axes.

Referring now to FIG. 5, additional details of one embodiment of a compensation circuit 40Y constructed in accordance with the present invention are illustrated. The input terminal 4lY carries a signal representing V,-, the programmed velocity along the contour, while the input terminal 42Y carries a signal representing V,, the actual velocity of the cutting tool along the opposite (X) axis. The output terminal 43Y is connected to the Y axis closed position loop as shown in FIG. 4 to modify the Y axis position error signals. The compensation circuit 40Y includes a multiplier circuit 45Y connected to the input terminals 4lY and 42Y. A resistor 46Y has a first terminal connected to the input terminal 42Y and a second terminal connected'to the input terminal 47Y of an operational amplifier 48Y. An output terminal 49Y of the operational amplifier 48Y is the output terminal of the multiplier In multiplier circuit 45Y, the V, signal is applied to input terminal 47Y of operational amplifier 48Y. The output of operational amplifier 48Y is made equal to the quotient expressed in equation (3) by varying feedback around operational amplifier 48Y as an inverse function of the value of velocity V,. A bank of resistors 50Y57Y, each of which is connected in series with a switch in a bank of switches 60Y-67Y, provides a negative feedback path from the output to the input of operational amplifier 48Y. The switches 60Y-67Y are opened and closed individually by a switching circuit 68 which receives and decodes a signal representing programmed velocity V,-. Generally, as V, increases, switching circuit 68 decreases the effective feedback impedance by closing more of the switches 60Y-67Y.

As was explained with respect to FIG. 3, the direction of compensation must be chosen. Therefore, the Cos signal appearing on output terminal 49Y is applied to a polarity circuit 72Y having an input terminal 73Y and an output terminal 74Y. A first switch 75Y is connected between the terminals 73Y, amplifier 77Y and a resistor 78Y are all connected in series across the switch 75Y. A resistor 79Y is connected across the operational amplifier 77Y. The values of the resistors 78Y and 79Y are chosen so that the operational amplifier 77Y has a gain ofl. Switches75Y and 76Y are ganged so that one is closed when the other is open. When the switch 75Y is closed, the output appearing at the terminal 49Y is directly coupled to the output terminal 74Y. When the switch 76Y is closed, the signal applied to terminal 74Y is equal in magnitude and opposite in polarity to the signal on the output terminal 49Y.

Thus far, a signal indicative ofthe direction of compensation and the value of Cos 0 has been provided. To produce the compensation vector C this signal is multiplied by the tool wear magnitude din an offset circuit 80Y. The magnitude of compensation d to be provided corresponds to a value of current to be superimposed on the X axis servomotor position command signal. Therefore, a variable resistance is connected between the terminals 80Y and 43Y so that the desired current will flow through the offset circuit 80Y for a given voltage appearing at the input terminal 8IY. As shown in FIG. 5, the variable resistance consists of'a bank of resistors 83Y-90Y each connected in series with one switch in a bank of switches 93Y-l00Y, The resistor-switch series combinations are connected in parallel between the terminals 81Y and 43Y. The value of each of the resistors 83Y-90Y is chosen so that a current corresponding to a given magnitude oftool wear compensation flows therethrough.

For example, assume that the discriminator circuits 26X and 26Y are arranged to produce an analog command signal in which a command signal having a level of 0.25 ma commands the servomotor II or 13 to which it is coupled to move the cutting tool 3 a distance of 0. I00 inch. Let it further be assumed that the cutting tool motion is on the X axis and that the magnitude 1! of tool wear is 0.0l0 inch. In this situation, C 0, and 0.0l0 inch. The voltage at the output terminal 49Y could be H) volt, representing Cos 6 where!) 0. A compensation signal having a magnitude of(0.0l0"/0. l00) X 0.25 ma, or 0.025 ma must be provided at the output terminal 43Y. Therefore, using Ohm's law, a resistance R having a value of R LOO/0.025) ma, or 40,000 ohms, is connected between the terminals 8lY and 43Y.

Other forms of an offset circuit are described following a description of a further embodiment of a compensating circuit 40Y. The offset circuit 80Y of FIG. is particularly suitable where it is desired to provide a thumbwheel switch arrangement for conveniently manually setting the magnitude :1 of compensation. The compensating circuit 40X is arranged similarly. However, since the input to the terminal 42X is indicative of V,,, the output at the terminal 49X (FIG. 6) is equal to Sin 6. It is noted that the correlation ofinput voltage to output current of the offset circuits 80X and 80Y must be the same for proper compensation.

Summarizing, an output current corresponding to C, is superimposed on the X position command signal and the current corresponding to C is superimposed on the Y position command signal so that a motion indicated by the vector C as shown in FIG. 3 is superimposed on the vector V and desired compensation is achieved.

As seen in FIG. 6, the variable resistance connected between the terminals 8lY and 43Y could comprise a potentiometer Y, one end of the potentiometer being connected to the terminal 8IY and the wiper arm of the potentiometer being connected to the terminal 43Y. The offset circuit 80X may be similarly arranged. Since in many cutting operations, the cutting tool 3 wears at a constant rate, the magnitude of d increases nearly linearly. Therefore, the arrangement of FIG. 6 may be utilized to automatically adjust the resistance Of the offset circuits 80X and 80Y as the cutting tool 3 wears. A

timer motor H0 is provided and is energized from a regulated source (not shown) to provide a constant speed output. The motor H0 is coupled to a variable gearing arrangement Ill having an output shaft 112 so that the ratio of revolutions of the motor to the shaft 112 may be set in accordance with the rate of tool wear. The output shaft 112 is mechanically coupled to a mechanical adjusting means US which is mechanically coupled to the wiper arms ofthe potentiometers l05Y and l05X respectively connected in the offset circuits 80Y and 80X respectively. The potentiometers l05X and IOSY have identical resistance versus angular displacement of wiper arm characteristics so that they are simultaneously identically adjusted as the motor 110 rotates. The mechanical adjusting means 113 may be preset so that the values of the potentiometers [05X and l05Y correspond to the initial values of compensation to be provided. An indicator 114 may be provided on the variable gear arrangement ill to set the gear ratio in terms of tool life, which corresponds to the rate of wear on the cutting tool 3.

Another form of compensation circuit 40 including another form of offset circuit is illustrated in FIG. 7. The operation is explained with reference to the compensating circuit 40Y. Once again, the input terminal 4|Y is connected to the data input unit 20 to receive data indicative of V,-. The input terminal 42Y is connected, however, to the output terminal 22X of function generator 2l to receive a signal representing programmed rather than actual velocity along the X axis. The compensating circuit 40Y in this embodiment includes a'multiplier circuit 145Y which provides a voltage indicative ofCos 0. The compensating circuit l45Y includes a first digital-toanalog converter l30Y having an input connected to the input terminal 42Y and an output terminal I32Y. A second digital to-analog converter I34Y is provided having input connected to the input terminal 4lY, an output terminal I36Y, and a feedback terminal l37Y. The digital-to-analog converter I34Y is connected in the feedback loop of an operational amplifier 139Y having a first input terminal connected to the output terminal 132Y of the digital-to-analog converter Y and a second input terminal connected to the output terminal l36Y of the digital-to-analog converter I34Y. An output terminal I42Y of the operational amplifier 139Y is connected to the feedback input terminal l37Y of the digital-to-analog converter 134Y. A capacitor I38Y is connected across feedback loop of the operational amplifier l39Y so that its output is smoothed and comprises a direct current output. The multiplier circuit l45Y operates in the following manner.

Let it be assumed that a vector V is programmed having a velocity of 10 inches per minute and that this velocity is represented by an output of IO X l0- pulses per minute produced by the data input unit 20. This pulse train indicative of the vector V is applied to the input terminal 4IY at the digital-to-analog converter 134Y. As pulses are applied to the digital-to-analog converter l34Y, resistors included therein are rendered conductive during each pulse duration to vary the gain of the operational amplifier I39Y in accordance with the magnitude of the vector V. Let it further be assumed that the 0 45, so that the component of motion V, is represented by an output of 7.07 X 10 pulses per minute appearing at the output terminal 22X of the function generator 21. These pulses indicative of V, are applied to the input terminal 42Y at digital-toianalog converter 130Y. Each pulse applied to the digital-to-analog converters 130Y and I34Y turns them on for a fixed period of time. Thus, time modulated outputs are applied to the input terminals of the operational amplifier I39Y. Since the gain of the operational amplifier l39Y varies with the vector V, the voltage appearing at the output terminal 142Y is proportional to the ratio of the numbers of input pulses respectively supplied to its first and'second input terminals. In thepresent example, this ratio is equal to (7.07 X "/.l0.0 X 10) or 0.707 which is equal to the cosine of 45. Thus the voltage appearing at the terminal I42Y is indicative of Cos 0. Similarly, the voltage appearing at the terminal I42 X in the compensating circuit X is proportional to the ratio of Y component of motion to the resultant motion, and is thus indicative of Sin 6. It should be noted here that the multiplier circuit 145Y operates similarly to the multiplier circuit 45Y of FIG. 5 in that an input signal indicative of V, is supplied to an operational amplifier, the gain of which is controlled by an input signal indicative of the vector V. In the embodiment of FIG. 7, however, the input signals are digital rather than analog.

The multiplier circuit I45Y also acts as a polarity circuit for determining the direction of compensation in the following manner. First and second positive and negative polarity terminals 150Y and lSIY are provided in the digital-to-analog converter I30Y to determine the polarity of its output. One of the two terminals IY and ISIY is energized by any convenient means. One such convenient means comprises the further provision of preparatory command signals in the instructions provided to the data input unit 20. To implement the provision of preparatory command signals, polarity terminals I54-and 155 are included in the data input unit 20. Terminals- I54 and I55 are coupled respectively to the polarity terminals ,ISOY and I5IY. The same polarity terminals I54 and I55 are also respectively coupled to the corresponding X polarity terminals I50X and I51. If desired, a manual switching control (not shown), may be incorporated in the control console I of FIG. I in place of the polarity terminals 154 and 155. H I

An offset circuit l80Y having an input terminal lY connected to the output terminal I42Y and an output at the output terminal 43Y is provided to relate the output of the mul tiplier circuit 145Y to themagnitude of tool wear correction to be provided. The offset circuit I80Y includes a resistor I62Y, an operational amplifier 166Y having a first input terminal connected to resistor I62Y and an output terminal, and a coupling resistor l67Y. A digial-to-analog converter l70Y is connected in the feedback loop of the operational amplifier I66Y by connecting its feedback input terminal to the output terminal of the operational amplifier I66Y and its output terminal to a second input of the operational amplifier l66Y.

In this embodiment, the tool wear correction is varied automatically in correspondence with the actual rate of wear of the cutting tool 3. In order to accomplish this, a counter I is connected to an input terminal 17IY of the digital-to-analog converter l70Y. A source of clock pulses is coupled to a digital multiplier 186 which provides an output to the counter 175. The digital multiplier is arranged to divide the clock pulse rate so that the number in the counter increases at a rate proportional to tool wear. The function of the digital multiplier I86 is similar to that of the variable gear arrangement III in the mechanical embodiment of FIG. 6. A preset register 187 is also coupled to the counter 185 so that at the initiation of operation, the number in the counter may be set to correspond to an initial degree of tool wear. The function of the present register 187 is similar to that of the mechanical adjusting means I13 of the embodiment illustrated in FIG. 6.

The offset circuit lY operates in the following manner. The value of the resistor I67Y is chosen to provide a reference gain for the operational amplifier 16 6Y. As the counter counts in response to pulses applied from the digital multiplier I86, resistors included in the digital-toanalog converter l70Y are selectivelY rendered conductive to adjust the gain of the operationAl amplifier l66Y. The gain of the operational amplifier I66Y is thus made proportional to the contents of counter 175. Since the preset register I87 may be set to provide a number in the counter proportional to an initial degree of tool wear. and since the digital multiplier I86 provides pulses to the counter at a'rate corresponding to that of the wear of the cutting tool 3, the output signal at terminal 43Y corresponds to the desired degree of compensation.

Similarly, the output of the counter 175 is coupled to the terminal 17 IX and the compensationcircuit 40X so that the gain of the operational amplifier 166Y is also proportional to the number in the counter 175. The outputs appearing at the terminals 43Y and 43X are coupled to the X and Y position loops, respectively, to compensate the position of the cutting tool in a manner explained above. It should be noted that the number supplied by the preset register to the counter may be set by thumbwheel switches included in the group of switches denoted by the reference numeral 5 in FIG. 1.

The offset circuit l80Y shown in this figure is suitable for use in the embodiments of FIGS. 5 and 6. Similarly, the offset circuits of FIGS. 5 and 6 could be included inthe compensation circuits 40X and 40Y of the arrangement of FIG. 7.

It is thus seen that the present invention comprehends the provision of correction signals superimposed on X and Y axis position command signals so that the path of a cutting tool relative to a workpiece is always offset by a compensation vector C which is always normal to the vector V representing the relative motion and has a magnitude equal to that of cutting tool wear. In practical application, the present system has operated to provide cutting tolerances within 0.001 inch.

The specification has shown various embodiments of the present invention toenable those skilledin the art to make many modifications of the circuitry disclosed to produce a control system constructed in accordance with the present invention.

I. In a control system for commanding the motion of first and second drive means for producing relative motion between a cutting tool and a workpiece in an automatic machine tool and including first and second means providing command signals to firstand secondclosed position control loops for driving said first and second drive means, a data input unit providing output data indicative of the desired resultant commanded motion, and a function generator having an input connected to said data input means and first and second outputs connected to said first and second command means respectively for producing first and second outputs respectively indicative of the desired motion in said first and second degrees of freedom, means for compensating the relative motion for dimensional errors introduced by wear on a cutting tool comprising in combination:

a. velocity indicating means for producing an output indicative of the motion of said first drive means;

b. a multiplier circuit having first and second inputs and an output, said first input being connected to said velocity indicating means and said second input being coupled to the output of said data input means, said multiplier circuit providing an output proportional to the first input and having a gain varying in response to the magnitude of the output of said data input means;

c. an offset circuit having an input coupled to the output of said multiplier circuit, said offset circuit being settable to modify the magnitude of the output of said multiplier circuit in accordance with the magnitude of the dimensional error to be compensated; and

d. means coupling the output of said offset circuit to the second means providing command signals to modify the command signal supplied to the second closed position control loop.

2. A control system according to claim I wherein said velocity indicating means comprises a tachometer coupled to said first drive means.

polarity reversing means comprises:

3. A control system'according to claim 2 wherein said multiplier circuit comprises:

a. a first resistor having a first terminal connected to the first input of said multiplier circuit;

b. an operational amplifier having a first input terminal connected to the second terminal of said first resistor and an output terminal connected to the output terminal of said multiplier circuit;

c. an'adjustable resistance connected across said operational amplifier; and

d. means connected to the second input of said multiplier circuit for varying said adjustable resistance across said operational amplifier in proportion to the output of said data input means so that the ratio of said adjustable resistance to the value of said first resistor is inversely proportional to the ratio of the output of said data input means and a predetermined maximum velocity to provide an output of said multiplier circuit which is representative of a geometrical function of the angle of relative motion with respect to the axis defining the degree of freedom in which said first drive means produces motion.

4. A control system according to claim 3 wherein said adjustable resistance comprises a plurality of resistors and a switch connected in series with each resistor, and means connecting each combination of a resistor and a switch in parallel across said operational amplifier, and in which said connecting means being responsive to the output of said data input means comprises a switching circuit having an input connected to the second input of said multiplier circuit, said switching circuit being arranged to vary the resistance connected across said operational amplifier as the output of said data input means varies.

5. A control system according to claim 3 further comprising polarity reversing means connected between the output of said multiplier circuit and the input of said offset circuit for determining the direction ofcompensation to be provided,

6. A control system according to claim 5 wherein said a. a first switch connected in series between the output of said multiplier circuit and the input ofsaid offset circuit;

b. a second switch, an operational amplifier, and a first resistor all connected in series across said first switch; and

c. a second resistor connected across said operational amplifier, said first and second switches being ganged so that when one of said switches is closed, the other is open, and said operational amplifier having a gain ofminus one.

7. A control system according to claim 6 further comprising a second compensating means and a tachometer coupled to said second drive means, the output of said tachometer being coupled to the input of said compensating means and the output of said second compensating means being coupled to modify the command signals applied to said first closed control loop, the offset circuits included in said first and second compensating means being set to modify the output of each multiplier circuit in the same proportion.

8. A control system according to claim 7 wherein each of said offset circuits comprises a variable resistance being settable so that its value inversely corresponds to the magnitude of compensation to be provided, and further comprising a timer motor mechanically coupled to adjust said resistances, the rate of adjustment produced by said motor being chosen to correspond to the rate of tool wear during a cutting operation.

9. A control system according to claim 1 wherein said velocity indicating means comprises the first output of said function generator.

10. A control system according to claim 9 wherein the output of said data input means and said function generator are digital and said multiplier circuit comprises:

a. a first digital-to-analog converter having an input connected to the first input ofsaid multiplier circuit;

b. a second digital-to-analog converter having an input connected to the second input of said multiplier circuit; and

c. an operational amplifier having first and second inputs respectively connected to the outputs of said first and second digitaI-to-analog converters and an output connected to the output terminal of said multiplier circuit, said second digital-to-analog converter being connected between the output terminal of said operational amplifier and its second input terminal to vary the gain thereof in response to the output of the data input unit, whereby said multiplier circuit produces an output proportional to the pulse rate input ratio of said second input to said first input of said multiplier circuit.

11. A control system according to claim 10 further comprising a second compensating means having an input coupled to the second output of said function generator and an output coupled to modify the command signals supplied to said first closed control loop.

12. A control system according to claim 1 I wherein;

a. said offset circuit in each compensating arrangement comprises an operational amplifier having a first input terminal, a second input terminal, and an output terminal; and

b. means connected across each of said operational amplifiers for varying its gain in proportion to the degree of compensation to be. provided, said means for varying the gain of each of said operational amplifiers comprising a digital-to-analog converter connected between the output terminal of each of said operational amplifiers and its second input terminal, a digital multiplier for connection to a source of clock pulses, said digital multiplier producing a pulse rate indicative of the rate of tool wear, and a counter connected to said digital multiplier and providing an input to each of said digital-to-analog converters, whereby the gain of said operational amplifiers is proportional to the number in the counter.

l3. A control system according to claim 12 further compris ing a preset register connected to said counter for setting a number in said counter indicative of an initial degree of com pensation to be provided.

M. A control system according to claim 1 wherein said offset circuit comprises a variable resistance, said resistance being settableto inversely correspond to the magnitude of compensation to be provided.

15. A control system according to claim 14 further comprising a timer motor mechanically coupled to adjust said variable resistance, the rate of adjustment produced by said motor corresponding to the rate oftool wear during a cutting operation.

16. A control system according to claim 1 wherein said offset circuit comprises an operational amplifier having a first input terminal, an output terminal, and means connected across said operational amplifier for varying its gain in proportion to the degree of compensation to be provided.

17. A control system according to claim 16 wherein said means for varying the gain outside operational amplifier comprises a digital-to-analog converter connected between the output terminal of said operational amplifier and its second input terminal for varying the gain ofsaid operational amplifier, a digital multiplier for connection to a source of clock pulses, a counter coupled to said digital multiplier and providing an output to said analog-to-digital converter indicative of the expected rate of tool wear.

18. A control system according to claim 17 further comprising a preset register connected to said counter for setting a number in said counter indicative of an initial degree of compensation to be provided.

19. In a control system in which a first source of input data is provided indicative of the desired relative motion between a workpiece and a tool and first and second inputs are provided respectively indicative of the desired motion of first and second drive means and first and second degrees of freedom to produce the desired first and second components of relative motion, a method for compensating the relative motion for dimensional errors due to wear on the cutting tool comprising the steps of:

a. measuring the velocity of said first drive means to produce a first velocity indicating signal;

b. multiplying said first velocity indicating signal by the ratio of the instantaneous velocity of said relative motion to a maximum velocity to produce a first multiplier output;

. multiplying first said output by plus or minus one to cor respond to motion in first or second directions within said first degree of freedom to produce a first signal indicative of the direction of compensation to be provided in said second degree of freedom;

d. multiplying said last-named signal to produce an offset signal corresponding to the magnitude of compensation to be provided; and y e. utilizing said offset signal to modify the command signals applied to said second drive means.

20. A method according to claim 17 further comprising the steps of:

ratio of the instantaneous velocity of said relative motion to said maximum velocity to produce a second multiplier output;

c. multiplying said second multiplier output by plus or minus one to produce a second signal indicative of the direction of compensation to be provided in said first degree of freedom;

d. multiplying said last-named signal to produce an offset output corresponding to the magnitude of compensation to be provided; and

e. utilizing said offset signal to modify command signals applied to said first drive means.

21. A method according to claim 18 wherein the input data indicative of the desired velocity of each drive means is measured.

22. A method according to claim 19 wherein the input data indicative of the desired velocity of each drive means is measured. 

1. In a control system for commanding the motion of first and second drive means for producing relative motion between a cutting tool and a workpiece in an automatic machine tool and including first and second means providing command signals to first and second closed position control loops for driving said first and second drive means, a data input unit providing output data indicative of the desired resultant commanded motion, and a function generator having an input connected to said data input means and first and second outputs connected to said first and second command means respectively for producing first and second outputs respectively indicative of the desired motion in said first and second degrees of freedom, means for compensating the relative motion for dimensional errors introduced by wear on a cutting tool comprising in combination: a. velocity indicating means for producing an output indicative of the motion of said first drive means; b. a multiplier circuit having first and second inputs and an output, said first input being connected to said velocity indicating means and said second input being coupled to the output of said data input means, said multiplier circuit providing an output proportional to the first input and having a gain varying in response to the magnitude of the output of said data input means; c. an offset circuit having an input coupled to the output of said multiplier circuit, said offset circuit being settable to modify the magnitude of the output of said multiplier circuit in accordance with the magnitude of the dimensional error to be compensated; and d. means coupling the output of said offset circuit to the second means providing command signals to modify the command signal supplied to the second closed position control loop.
 2. A control system according to claim 1 wherein said velocity indicating means comprises a tachometer coupled to said first drive means.
 3. A control system according to claim 2 wherein said multiplier circuit comprises: a. a first resistor having a first terminal connected to the first input of said multiplier circuit; b. an operational amplifier having a first input terminal connected to the second terminal of said first resistor and an output terminal connected to the output terminal of said multiplier circuit; c. an adjustable resistance connected across said operational amplifier; and d. means connected to the second input of said multiplier circuit for varying said adjustable resistance across said operational amplifier in proportion to the output of said data input means so that the ratio of said adjustable resistance to the value of said first resistor is inversely proportional to the ratio of the output of said data input means and a predetermined maximum velocity to provide an output of said multiplier circuit which is representative of a geometrical function of the angle of relative motion with respect to the axis defining the degree of freedom in which said first drive means produces motion.
 4. A control system according to claim 3 wherein said adjustable resistance comprises a plurality of resistors and a switch connected in series with each resistor, and means connecting each combination of a resistor and a switch in parallel across said operational amplifier, and in which said connecting means being responsive to the output of said data input means comprises a switching circuit having an input connected to the second input of said multiplier circuit, said switching circuit being arranged to vary the resistance connected across said operational amplifier as the output of said data input means varies.
 5. A control system according to claim 3 further comprising polarity reversing means connected between the output of said multiplier circuit and the input of said offset circuit for determining the direction of compensation to be provided.
 6. A control system according to claim 5 wherein said polarity reversing means comprises: a. a first switch connected in series between the output of said multiplier circuit and the input of said offset circuit; b. a second switch, an operational amplifier, and a first resistor all connected in series across said first switch; and c. a second resistor connected across said operational amplifier, said first and second switches being ganged so that when one of said switches is closed, the other is open, and said operational amplifier having a gain of minus one.
 7. A control system according to claim 6 further comprising a second compensating means and a tachometer coupled to said second drive means, the output of said tachometer being coupled to the input of said compensating means and the output of said second compensating means being coupled to modify the command signals applied to said first closed control loop, the offset circuits included in said first and second compensating means being set to modify the output of each multiplier circuit in the same proportion.
 8. A control system according to claim 7 wherein each of said offset circuits comprises a variable resistance being settable so that its value inversely corresponds to the magnitude of compensation to be provided, and further comprising a timer motor mechanically coupled to adjust said resistances, the rate of adjustment produced by said motor being chosen to correspond to the rate of tool wear during a cutting operation.
 9. A control system according to claim 1 wherein said velocity indicating means comprises the first output of said function generator.
 10. A control system according to claim 9 wherein the output of said data input means and said function generator are digital and said multiplier circuit comprises: a. a first digital-to-analog converter having an input connected to the first input of said multiplier circuit; b. a second digital-to-analog converter having an input connected to the second input of said multiplier circuit; and c. an operational amplifier having first and second inputs respectively connected to the outputs of said first and second digital-to-analog converters and an output connected to the output teRminal of said multiplier circuit, said second digital-to-analog converter being connected between the output terminal of said operational amplifier and its second input terminal to vary the gain thereof in response to the output of the data input unit, whereby said multiplier circuit produces an output proportional to the pulse rate input ratio of said second input to said first input of said multiplier circuit.
 11. A control system according to claim 10 further comprising a second compensating means having an input coupled to the second output of said function generator and an output coupled to modify the command signals supplied to said first closed control loop.
 12. A control system according to claim 11 wherein; a. said offset circuit in each compensating arrangement comprises an operational amplifier having a first input terminal, a second input terminal, and an output terminal; and b. means connected across each of said operational amplifiers for varying its gain in proportion to the degree of compensation to be provided, said means for varying the gain of each of said operational amplifiers comprising a digital-to-analog converter connected between the output terminal of each of said operational amplifiers and its second input terminal, a digital multiplier for connection to a source of clock pulses, said digital multiplier producing a pulse rate indicative of the rate of tool wear, and a counter connected to said digital multiplier and providing an input to each of said digital-to-analog converters, whereby the gain of said operational amplifiers is proportional to the number in the counter.
 13. A control system according to claim 12 further comprising a preset register connected to said counter for setting a number in said counter indicative of an initial degree of compensation to be provided.
 14. A control system according to claim 1 wherein said offset circuit comprises a variable resistance, said resistance being settable to inversely correspond to the magnitude of compensation to be provided.
 15. A control system according to claim 14 further comprising a timer motor mechanically coupled to adjust said variable resistance, the rate of adjustment produced by said motor corresponding to the rate of tool wear during a cutting operation.
 16. A control system according to claim 1 wherein said offset circuit comprises an operational amplifier having a first input terminal, an output terminal, and means connected across said operational amplifier for varying its gain in proportion to the degree of compensation to be provided.
 17. A control system according to claim 16 wherein said means for varying the gain outside operational amplifier comprises a digital-to-analog converter connected between the output terminal of said operational amplifier and its second input terminal for varying the gain of said operational amplifier, a digital multiplier for connection to a source of clock pulses, a counter coupled to said digital multiplier and providing an output to said analog-to-digital converter indicative of the expected rate of tool wear.
 18. A control system according to claim 17 further comprising a preset register connected to said counter for setting a number in said counter indicative of an initial degree of compensation to be provided.
 19. In a control system in which a first source of input data is provided indicative of the desired relative motion between a workpiece and a tool and first and second inputs are provided respectively indicative of the desired motion of first and second drive means and first and second degrees of freedom to produce the desired first and second components of relative motion, a method for compensating the relative motion for dimensional errors due to wear on the cutting tool comprising the steps of: a. measuring the velocity of said first drive means to produce a first velocity indicating signal; b. multiplying said first velocity indicating signal by the ratio of the instantaneous velocity of saiD relative motion to a maximum velocity to produce a first multiplier output; c. multiplying first said output by plus or minus one to correspond to motion in first or second directions within said first degree of freedom to produce a first signal indicative of the direction of compensation to be provided in said second degree of freedom; d. multiplying said last-named signal to produce an offset signal corresponding to the magnitude of compensation to be provided; and e. utilizing said offset signal to modify the command signals applied to said second drive means.
 20. A method according to claim 17 further comprising the steps of: a. measuring the velocity of said second drive means to produce a second velocity indicating signal; b. multiplying said second velocity indicating signal by the ratio of the instantaneous velocity of said relative motion to said maximum velocity to produce a second multiplier output; c. multiplying said second multiplier output by plus or minus one to produce a second signal indicative of the direction of compensation to be provided in said first degree of freedom; d. multiplying said last-named signal to produce an offset output corresponding to the magnitude of compensation to be provided; and e. utilizing said offset signal to modify command signals applied to said first drive means.
 21. A method according to claim 18 wherein the input data indicative of the desired velocity of each drive means is measured.
 22. A method according to claim 19 wherein the input data indicative of the desired velocity of each drive means is measured. 